Method of metallurgically bonding a stator bar

ABSTRACT

A method for metallurgically bonding a stator bar to a coupling to reduce the incidence of leak paths resulting from corrosion. The stator bar comprises strands through which a liquid coolant can flow. Adjacent ends of the strands are received in an interior cavity of the coupling through an opening in the coupling. A joining material is provided on a first portion of the stator bar within the coupling opening and adjacent the ends of the strands. The first portion is heated to melt the joining material. At essentially the same time, a second portion of the stator bar outside the coupling is also heated. Once the joining material is suitably molten, the first portion is allowed to cool while the second portion remains heated, thereby causing the joining material nearest the ends of the strands to solidify first.

CROSS REFERENCE TO RELATED APPLICATIONS

This is a division patent application of U.S. patent application Ser.No. 10/249,685, filed Apr. 30, 2003 now U.S. Pat. No. 7,073,247. Thecontents of this application are incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present invention generally relates to the stator bar endconnections of a liquid-cooled generator. More particularly, thisinvention relates to a method of metallurgically joining copperconductors of a stator bar to a fluid coupling, whereby the joint issolidified in a manner that reduces the incidence of defect-inducedcorrosion.

Stator bars of a liquid-cooled electrical generator typically comprise acombination of solid and hollow copper strands, with opposing ends ofthe strands being brazed to a fluid coupling, referred to herein as aclip. The clip serves as both an electrical and fluidic connection forthe stator bar. For purposes of the latter, the clip defines an interiorchamber, referred to as a water box, into which the ends of the strandsextend through an opening in the clip to permit flow of a liquidcoolant, typically deionized water, between the clip and hollow strands.The coolant flows to or from the clip through a hose coupled to a hoseconnection of the clip. A braze metal metallurgically bonds the strandsto each other and joins the clip to the peripherally outermost strandsof the stator bar. Brazing is typically performed by placing a brazealloy, such as a preform formed of the alloy, between the strands andclip, and then heating the strands and clip with a torch or by inductionheating to cause the braze alloy to melt and flow by capillary action.Once solidified, the braze alloy metallurgically bonds the strands toeach other and to the fluid coupling so as to form a fluid-tightbrazement between the stator bar and clip.

Over time, leaks may develop at the bar-clip connection as a result ofthe development of a leak path between strands and/or between strandsand the clip. As reported in commonly-assigned U.S. Pat. Nos. 5,605,590and 5,796,189, both to Manning et al., one leak mechanism that has beenidentified is attributed to corrosion of the braze alloy. Corrosion isbelieved to be initiated by stagnant water residing within concavepockets that are present in the surface of the brazement between thestrands and clip. While Manning et al. disclose techniques by which theincidence of leakage can be reduced, there is an ongoing effort tofurther reduce the likelihood of leaks in view of the considerabledowntime and cost involved in repairing such leaks.

BRIEF SUMMARY OF THE INVENTION

The present invention provides a method for metallurgically bonding astator bar to a fluid coupling in a manner that reduces the incidence ofleak paths resulting from corrosion. The stator bar is of the typecomprising a group or bundle of strands, at least some of which arehollow so that a cooling fluid can flow through the stator bar and fluidcoupling for the purpose of cooling the stator bar. Adjacent ends of thestrands are received in an interior cavity of the fluid coupling throughan opening in the fluid coupling. The method of this invention iscapable of reducing the incidence of leakage between the strands and thecoupling by controlling the manner in which the material used tometallurgically bond the strands and coupling is solidified.

The method generally involves providing the joining material on a firstportion of the group of strands that is within the opening of the fluidcoupling and adjacent the ends of the strands. A first heating means isplaced in proximity to the opening of the fluid coupling, and a secondheating means is placed in proximity to a second portion of the group ofstrands that is outside the opening. The first heating means is thenoperated to sufficiently heat the first portion of the group of strandsto melt the joining material. The second heating means is also operatedto heat the second portion of the group of strands. Once the joiningmaterial is suitably molten, the first heating means is operated toallow the first portion of the group of strands to cool and therebysolidify the joining material nearest the ends of the strands. However,the second heating means is operated further to continue heating thesecond portion of the group of strands. The second heating means isoperated to allow the second portion of the group of the strands to coolin a manner that causes the joining material at the first portion of thegroup of strands to solidify in a direction away from the ends of thestrands and toward the second portion. Once solidified, the joiningmaterial forms a joint that metallurgically bonds the strands to eachother and the first portion of the group of strands to the fluidcoupling.

As a result of the directional solidification of the joining material atthe joint between the stator bar and fluid coupling,solidification-related surface defects that may form in the joint areconcentrated in a region of the joint farthest from the ends of thestrands. According to the invention, by eliminating or at leastsignificantly reducing the presence of defects in the surface of thejoint contacted by the coolant flowing through the strands and fluidcoupling, the incidence of corrosion brought on by crevice corrosion canbe significantly reduced. As a result, leaks attributed to the onset ofcrevice corrosion are less likely to occur.

Other objects and advantages of this invention will be betterappreciated from the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a fragmentary cross-sectional view of a stator bar-clipconnection undergoing a brazing operation in accordance with anembodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 represents a liquid-tight connection 10 between a liquid-cooledstator bar 12 and a fluid coupling, referred to herein as a clip 14. Theconnection 10, stator bar 12 and clip 14 are representative ofcomponents found in a liquid-cooled generator. Those skilled in the artwill appreciate that the appearance and construction of the connection10 are merely representative, and that the teachings of this inventionare applicable to a variety of other situations where a fluid-tightjoint is desired.

As illustrated in FIG. 1, the stator bar 12 includes a plurality ofstrands 16, at least some of which are hollow for carrying a liquidcoolant to or from the clip 14. The strands 16 are typically assembledto form a bundle comprising an array of strands 16, with additionalstrands 16 being positioned behind those visible in FIG. 1. The strands16 are arranged so that their ends 28 are adjacent each other androughly coplanar, with the exception being that hollow strands 16preferably protrude beyond any solid strands 16 present in the bundle(for reasons that will become apparent from the following discussion).The strands 16 are formed of an electrically-conductive material, suchas copper. In the embodiment depicted in FIG. 1, the clip 14 is alsoformed of an electrically-conductive material, such as copper, to enablethe clip 14 to conduct current to or from the bar 12. The clip 14 isshown as having a closed body with an opening 18 at one end forreceiving the strands 16 of the stator bar 12. The clip 14 further hasan interior cavity 20 and a passage 22. The passage 22 is within aportion of the clip 14 that defines a fitting 24 to which a tube (notshown) can be coupled to provide both an electrical connection to thestator bar 12 and a fluidic connection for a liquid coolant, e.g.,deionized water, flowing through the stator bar 12. Alternatively, theclip 14 could be configured so that the electrical connection to thestator bar 12 is provided by a component other than the tube coupled tothe fitting 24.

According to conventional practice, the strands 16 are metallurgicallybonded to each other as well as to the interior wall that defines theopening 18 of the clip 14. A preferred material for forming this bond isa brazing material, such as a copper-phosphorous alloy, though the useof other bonding materials is foreseeable. Brazing material in the formof a paste, one or more solid preforms, etc., is typically placed in andaround the ends 28 of the strands 16, which are then inserted into theopening 18 of the clip 14. Heating the clip 14 (such as with aninduction coil 30 as shown in FIG. 1) causes the brazing material tomelt and flow, which is then allowed to cool to form a brazement 26 thatmetallurgically bonds the strands 16 together within the opening 18, andtherefore within the portion 32 of the stator bar 12 nearest the ends 28of the strands 16. Arranging the strands 16 so that hollow strands 16protrude beyond any solid strands 16 present in the bundle serves toinhibit the flow of the molten braze material into the open ends of thehollow strands 16. As indicated in FIG. 1, the brazement 26 also servesto bond this portion 32 of the stator bar 12 to the clip 14. As such,the brazement 26 is required to form a liquid-tight joint between theindividual strands 16 of the stator bar 12 and between the clip 14 andthe strands 16 located at the perimeter of the stator bar 12.

As reported in commonly-assigned U.S. Pat. Nos. 5,605,590 and 5,796,189to Manning et al., it has been observed that leaks occurring withinconnections of the type shown in FIG. 1 can be initiated by corrosion ofthe brazement 26 near the ends 28 of the strands 16 as a result of beingin contact with the liquid coolant. Corrosion can progress betweenstrands 16 and/or between the clip 14 and one or more strands 16 until acontinuous leak path extends completely through the brazement 26 to theexterior of the clip 14. Manning et al. further reported that corrosionof the brazement 26 is promoted as a result of stagnant liquid coolantwithin pockets defined in the surface of the brazement 26 near thestrand ends 28. While Manning et al. successfully reduce the incidenceof leakage by eliminating such pockets or sealing the leakage paths atthe surface of the brazement 26, investigations leading to the presentinvention showed that crevice corrosion can be initiated as a result ofvery small solidification defects, such as those formed by gas porosity,at the surface of the brazement 26 contacting the coolant. Theseinvestigations determined that such defects are concentrated in thebrazement 26 near the ends 28 of the strands 16, and therefore in thevery region of the brazement 26 that is most prone to corrosion as aresult of being in contact with the coolant. The basis for theconcentration of solidification defects near the ends 28 of the strands16 was attributed to the considerably greater thermal mass of the statorbar 12 as compared to the clip 14, resulting in the stator bar 12 actingas a heat sink so that the molten brazing material farthest from theends 28 of the strands 16 solidifies first, with solidification thenproceeding through the opening 18 in the clip 14 toward the ends 28 ofthe strands 16. As solidification proceeds, gas bubbles andsolidification shrinkage defects tend to be concentrated in the lastliquid metal to solidify, and therefore at the surface of the brazement26 near the strand ends 28, where they form surface defects.

As a solution, the present invention provides a method of forming thebrazement 26 so that solidification defects that may form in thebrazement 26 tend to accumulate or otherwise become concentrated in aregion of the brazement 26 away from the strand ends 28, preferably inthe region of the brazement 26 adjacent the exterior of the clip 14. Toachieve this result, the process of cooling the brazing material to formthe brazement 26 is controlled so that the brazing material initiallysolidifies adjacent the ends 28 of the strands 16, and thereaftersolidifies in the direction toward the exterior of the clip 14. In sodoing, gas porosity and other solidification defects that form duringcooling tend to accumulate within the region of the brazement 26farthest from the strand ends 28, and therefore out of contact with theliquid coolant, while the region of the brazement 26 that contacts theliquid coolant within the clip 14 (i.e., adjacent the strand ends 28) issubstantially defect-free. Because crevice corrosion will not occur ifan initial crevice (e.g., a surface defect) is not present, the presentinvention effectively eliminates or at least significantly reduces theoccurrence of leak paths initiated by crevice corrosion in the brazement26. This advantage of the invention can be achieved alone or in additionto the techniques taught by Manning et al. for avoiding other causes ofcorrosion in the brazement 26.

FIG. 1 represents several techniques, some optional, for achieving theabove. As discussed above, a first brazing material is provided on theportion 32 of the stator bar 12 (i.e., the bundle of strands 16) thatwill be positioned within the opening 18 of the clip 14. According to apreferred aspect of the invention, brazing material is also provided ona second portion 42 of the stator bar 12 spaced apart from the clip 14.In FIG. 1, the second portion 42 is surrounded by an annular-shapedfitting 34 that is positioned some distance from the clip 14. Forexample, if the stator bar 12 has a cross-section of about 2 by about 6cm, the fitting 34 may be placed about 1 to about 3 cm from the clip 14.Alternatively, the fitting 34 could be placed immediately adjacent butout of direct thermal contact with the clip 14, so that heat is notconducted directly between the clip 14 and fitting 34 during thesubsequent brazing operation, and the brazing materials do not flow intothe gap therebetween and commingle during brazing to form a unitarybrazement. To ensure the latter, a thermal-insulating spacer (not shown)could be positioned between the clip 14 and fitting 34.

In FIG. 1, the induction coil 30 is shown as being positioned inproximity to the opening 18 in the clip 14 so as to surround the portion32 of the stator bar 12. Similarly, a second induction coil 40 is shownis being in proximity to the fitting 34 so as to surround the secondportion 42 of the stator bar 12. During the brazing operation of thisinvention, the induction coils 30 and 40 are energized to heat the firstand second portions 32 and 42, respectively, of the stator bar 12 andthereby melt each of the brazing materials. As with the clip 14, thefitting 34 is preferably formed of copper or an alloy thereof. However,the fitting 34 could be formed of a variety of other materials that willmetallurgically bond to the strands 16. The material for the fitting 34can be chosen to have a higher electrical resistance than the materialof the clip 14 in order to couple more effectively with the inductioncoil 40 to achieve a greater heating effect. For example, if the clip 14is formed of copper, there are various copper alloys (e.g., brass) thatwill achieve this effect for the fitting 34.

Once the brazing material located in the first portion 32 of the statorbar 12 is suitably melted and has flowed by capillary action to wet thesurfaces of the strands 16 within the first portion 32, the inductioncoil 30 can be de-energized to allow the first portion 32 of the statorbar 12 to cool and thereby initiate solidification of the brazingmaterial. During this time, the second induction coil 40 continues toheat the fitting 34 and the portion 42 of the stator bar 12 within. As aresult, the brazing material nearest the ends 28 of the strands 16begins to solidify first, while the remaining brazing material,including the balance within the portion 32 of the stator bar 12 and allof the material within the portion 42 of the stator bar 12, remains in amolten state. With the induction coil 30 de-energized and the inductioncoil 40 energized, the brazing material within the portion 32 of thestator bar 12 gradually solidifies in a direction away from the ends 28of the strands 16 and toward the second portion 42 of the stator bar 12.This phase of the process is preferably continued until all of thebrazing material within the portion 32 has solidified. The secondinduction coil 40 is eventually de-energized to allow the second portion42 of the stator bar 12 to cool and thereby cause the brazing materialwithin to also solidify. At the conclusion of this process, the brazingmaterials have formed brazements 26 and 36 that metallurgically bond thestrands 16 to each other and the portions 32 and 42 of the stator bar 12to the clip 14 and fitting 34, respectively, with the brazement 26 beingfluid-tight to prevent leakage from the connection 10. Importantly, anysurface defects that might have formed in the brazement 26 areconcentrated in a region of the brazement 26 farthest from the ends 28of the strands 16 (i.e., immediately adjacent the outer extremity of theclip opening 18) as a result of the directional solidification of thebrazing material within the portion 32 of the stator bar 12.

Those skilled in the art will appreciate from the above that the fitting34 could be eliminated, such that the portion 42 of the stator bar 12 isdirectly heated by the induction coil 40. However, the fitting 34 ispreferably used because it provides a long, continuous conduction pathto the portion 42 and, if formed of a higher-resistance metal, enablesmore efficient heating of the portion 42. FIG. 1 represents the use ofadditional techniques that, in combination with the techniques describedabove, can promote the desired directional solidification of thebrazement 26. For example, a gas jet 44 can be directed at the clip 14during cooling to further ensure that the brazing material within theportion 32 of the stator bar 12 will begin to solidify at the ends 28 ofthe strands 16, instead of near the external entrance to the opening 18.FIG. 1 also schematically represents a heat sink 46 as being thermallycoupled to the clip 14. In one embodiment, the heat sink 46 may bebonded (e.g., brazed) or mechanically fastened to the clip 14.Alternatively, the heat sink 46 may be an integral portion of the clip14, e.g., a part of the casting from which the clip 14 is machined. Ineither case, the heat sink 46 is removed (e.g., debonded, unfastened orcut) from the clip 14 once the brazements 26 and 36 have solidified.

While the invention is described above as making use of induction coils30 and 40 to heat the clip 14 and fitting 34, other heating devicescould be used, a notable example being torches whose separate flames aredirected at the clip 14 and fitting 34. Furthermore, while the fitting34 is described as being brazed to the stator bar 12 simultaneously withthe clip 14, the fitting 34 could be brazed to the stator bar 12 priorto assembling the stator bar 12 with the clip 14. However, this approachwould require cleaning the strands 16 a second time before assembly withthe clip 14.

In view of the above, while the invention has been described in terms ofone or more particular embodiments, it is apparent that other formscould be adopted by one skilled in the art. Therefore, the scope of theinvention is to be limited only by the following claims.

1. A method of metallurgically bonding a stator bar to a coupling havingan interior cavity and an exterior opening thereto, the stator barcomprising a bundle of metal strands having adjacent ends, the methodcomprising the steps of: providing a first brazing material on a firstportion of the stator bar adjacent the ends of the strands and providinga second brazing material on a second portion of the stator bar spacedapart from the first portion; assembling the stator bar with thecoupling and an annular-shaped fitting so that the ends of the strandsare received in the coupling through the opening thereof, the firstportion of the stator bar is within the opening, and the second portionof the stator bar is outside the opening; placing a first heating meansin proximity to the coupling and placing a second heating means inproximity to the annular shaped fitting; operating the first heatingmeans to heat the coupling and the first portion therein and therebymelt the first brazing material, and operating the second heating meansto heat the annular shaped fitting and the second portion therein andthereby melt the second brazing material; operating the first heatingmeans to allow the first portion of the stator bar to cool and therebyinitiate solidification of the first brazing material nearest the endsof the strands while continuing to operate the second heating means tomaintain the second brazing material in a molten state, the firstbrazing material solidifying in a direction away from the ends of thestrands and toward the second portion of the stator bar; and thenoperating the second heating means to allow the second portion of thestator bar to cool and thereby cause the second brazing material tosolidify; wherein the first brazing material metallurgically bonds thestrands to each other and the first portion of the stator bar to thecoupling so as to form a fluid-tight first brazement therebetween, thesecond brazing material forms a second brazement that metallurgicallybonds the second portion of the stator bar to the annular shapedfitting, and any surface defects in the first brazement are concentratedin a region of the first brazement farthest from the ends of the strandsas a result of the directional solidification of the first brazingmaterial.
 2. The method according to claim 1, wherein the strands, thecoupling and the fitting are formed of copper or alloys thereof.
 3. Themethod according to claim 1, wherein the coupling and the fitting areformed of first and second materials, respectively, and the secondmaterial has a higher electrical resistivity than the first material. 4.The method according to claim 1, wherein at least some of the strandsare hollow and a remainder of the strands are not hollow.
 5. The methodaccording to claim 1, wherein the first and second heating means areinduction coils.
 6. The method according to claim 1, further comprisingthe step of directing a cooling gas at the coupling to promote coolingand solidification of the first brazing material before solidificationof the second brazing material.
 7. The method according to claim 1,wherein the coupling further comprises a heat sink thermally coupledthereto, the method further comprising the step of removing the heatsink after the step of operating the second heating means to allow thesecond portion of the stator bar to cool.
 8. The method according toclaim 7, wherein the heat sink is mechanically fastened to the coupling,and the step of removing the heat sink comprises unfastening the heatsink from the coupling.
 9. The method according to claim 7, wherein theheat sink is an integral portion of the coupling, and the step ofremoving the heat sink comprises cutting the heat sink from thecoupling.
 10. The method according to claim 1, wherein the fitting isimmediately adjacent but spaced apart from the coupling.
 11. The methodaccording to claim 1, wherein the first brazing material completelysolidifies before the second heating means is operated to cool thesecond portion of the stator bar.